Retrofit kit for modular lamp controller

ABSTRACT

Kits and methods and apparatus are provided for retrofitting a lamp for use with a modular lamp controller. In a representative embodiment, a kit includes a port connector, a first portion of a port adapter, a second portion of a port adapter, and a lock nut. The port connector is configured to accept a plug of the modular lamp controller. The first portion of a port adapter has a threaded section. The second portion of the port adapter has a threaded section. The first and second portions are configured to be placed in opposing relation about the port connector to securely surround the port connector while fitting into an opening within a fixture of the lamp. The lock nut screws onto the threaded sections of the first and second portions of the port adapter while placed in opposing relation surrounding the port connector to secure the port adapter and port connector within the opening.

BACKGROUND OF THE INVENTION

Each of U.S. Pat. Nos. 5,640,143; 5,986,357; 6,078,253; and 6,222,191 ishereby incorporated by reference.

1. Field of the Invention

The present invention relates generally to modular lamp controllers andmore particularly to methods and apparatus for retrofitting a lamp foruse with a modular lamp controller.

2. Background

Some HID lamps may be operated at reduced power. This can provide notonly energy savings and reduce cooling expenses, but can also reducepower consumption during peak demand periods. Some lamp types aresuitable light sources at both low and high power.

Conventional dimming systems for HID lamps have been available for manyyears. One scheme uses a ballast, two capacitors, a switch, and the HIDlamp. Several ballast types and configurations may be used. The mainrequirement for conventional dimming systems is that the electricalinclusion and removal of an impedance in the ballast circuit will causethe lamp to burn at desired power levels.

Most lamp manufacturers have made recommendations about the operation oftheir lamps with dimming systems. Typically, they require that the lampsmust be operated at full power for a minimum warm-up time before theyare allowed to operate at lower power. The lamps must also not beoperated below a minimum power.

A Constant Wattage Autotransformer (CWA) or constant wattage isolated(CWI) type ballast arrangement 100 is shown in FIG. 1 (prior art). Ifdotted line 101 is connected, this figure illustrates a CWA ballast. Ifit is not connected, the figure illustrates a CWI ballast. Themagnetically coupled coils 102 represent the ballast. Element 103 is theAC supply to the fixture, and element 104 is an earth ground connection.Element 105 is the capacitor in the fixture. Element 106 is the lampmogul, and element 107 is the lamp and/or lamp fixture, which may be anHID lamp.

FIG. 2 (prior art) shows the connections used for a conventional dimmingsystem 200 using a series capacitor arrangement. FIG. 3 (prior art)shows the connections used for a conventional dimming system 300 using aparallel capacitor arrangement. In both arrangements, the switch 203 isused to include or remove a connection to one terminal of one of thecapacitors in the circuit. The capacitor values for either series orparallel combination may be selected so that closing the switch operatesthe lamp at full power. When the switch is closed, the lamp is in serieswith a higher valued capacitance and operates at full power. When theswitch is open, the capacitance is reduced, and the lamp drops to alower power. Lumen output and color temperature completely changes formost lamps within a minute of a commutation of the switch.

To achieve a conventional dimming system, capacitor 105 of FIG. 1 hasbeen replaced by capacitors 201 and 202 in FIG. 2. Capacitor 105 of FIG.1 has been replaced by capacitors 301 and 302 in FIG. 3. Elements in theballast circuit that are in series may be manipulated with reference toposition and polarity without changing the performance. The threadedportion of the mogul base remains connected to an electrical potentialclose to neutral or earth ground for safety. The most likely connectionpoints based on ease-of-wiring to real fixtures are shown as elements204 and 205 of FIG. 2 and elements 303 and 304 of FIG. 3.

If the capacitance required for full power operation is 20 uF, and thecapacitance required for low power is 15 uF, suitable values of 201,202, 301, and 302 may be readily determined. In one example, they are20, 60, 15, and 5 uF respectively. A series combination will require twolarger value capacitors (20 and 60 uF) than a parallel combination (15and 5 uF) for the same full power (20 uF) and low power (15 uF) combinedvalues. This means that the series choice will most likely be physicallylarger than the parallel choice. For this reason, most conventionaldimming systems utilize parallel combinations, when available.

The series combination has lower voltage across the switched capacitorand switch. In FIG. 2, the voltage from ballast to lamp is dividedbetween capacitors 201 and 202 if switch 203 is open and across 201 whenthe switch is closed. In FIG. 3, the full voltage from ballast to lampis applied to both capacitors 301 and 302 when the switch is closed.

Installing a conventional dimming system is normally accomplished byreplacing the designed capacitor for a ballast with either two separatecapacitors or a dual capacitor. Inconveniently, conventional systemsrequire that the fixture be taken down and taken apart for installation.

In the configuration used with FIGS. 2 and 3, one controller may be usedto control and power many switches, but there is no way for thecontroller to know how long specific controlled lamps have been warmingup. If the lamp shuts-down for any reason, the controller may not runthat lamp for a new warm-up. If control is not present at the lampfixture, it may result in incorrect warm-up or no warm-up at all, whichmay damage lamp 107.

Any occupancy sensor (not shown) used with these conventional dimmingsystems is typically mounted separately from the switch and control. Theoccupancy sensor requires separate alignment and mounting, which may bevery inconvenient and time consuming.

Troubleshooting of conventional systems is time consuming, problematic,and often requires that the lamp be taken down and taken apart.

One significant problem with conventional dimmer systems is that it isdifficult to determine if a problem stems from the lamp, fixture, orsystem. Since the fixture must be taken apart for the installation,problems may be found anywhere from the lamp to the connection to themains. Damage may occur to the lamp in handling during installation ofthe system. The only way to remove the switch and control from thesystem is to remove the wire connections to them. Isolating part of thesystem for testing is difficult without first taking the fixture apart.

In addition, components may be damaged during the troubleshootingperiod. If too large a capacitor is installed in series with the lamp,it could cause excessive heat and damage components. If parallelcapacitors are reversed, it can cause the lamp to extinguish whenswitched to low power. This puts extra wear on the ignitor used withsome lamps. If too small a capacitor is installed in series with thelamp, it may not allow the lamp to start at all. This puts extra wear onthe ignitor and may damage the lamp electrodes over time.

If the control wiring is incorrect, every connected switch will beaffected. Improper or missing warm-up will cause premature end-of-lifeand lower lumen output for the lamps. If there is an open in thecircuit, the lamp will not ignite, but if an ignitor is used, it may runcontinuously. This will limit the life of the ignitor.

Further, with conventional systems, it is difficult to quickly see if alamp is stuck in either high or low power if there is no simple way tochange state. If a controller is present with the switch 203, it may notallow the lamp fixture to dim if it is in a warm-up period. Warm-upperiods may range from a few minutes to half an hour depending on thelamp. This is a long time to wait before testing a system. If the switch203 is independent at the lamp fixture 108, a control has to be wired toenable a test. There is no built-in mechanism to perform a simple testof conventional systems.

Troubleshooting is even more difficult when there are multiple lampfixtures 108 connected to one occupancy sensor (not shown). Not only arethere a larger number of connections per occupancy sensor, but also anoccupancy sensor used to control many fixtures is more likely to beimproperly aligned. The space the occupancy sensor has to cover istypically large, so small adjustments to sensor mounting may have largeeffects on coverage. Improper alignment of one sensor has a largerimpact on useful energy savings when it is controlling many fixtures.

A maximum in useful energy savings corresponds to a good match inoccupancy sensor coverage to illumination. If the occupancy sensorcoverage is too large such that a controlled lamp does not contributelight to a large portion of the coverage zone, it may burn at full powerwhen no one is using the light. If the sensor coverage is smaller thanthe contributed light of all controlled fixtures, the lights may not betriggered to full power reliably for the occupant.

In sum, conventional systems suffer from several shortcomings. Thereferenced shortcomings are not intended to be exhaustive, but ratherare among many that tend to impair the effectiveness of previously knowntechniques concerning the control, and particularly dimming control, oflamps. Other noteworthy problems may also exist; however, thosementioned here are sufficient to demonstrate that methodology appearingin the art have not been altogether satisfactory and that a significantneed exists for the techniques described and claimed herein.

In particular, a need exists for a modular lighting control systemsuitable for use with HID lamps that is easy to install, align,maintain, troubleshoot, and repair. More particularly, a need exists foreasily retrofitting lamp fixtures that do not include a port suitablefor use with a modular lamp controller.

SUMMARY OF THE INVENTION

Shortcomings of the prior art are reduced or eliminated by thetechniques discussed in this disclosure. In an illustrative embodiment,a modular lamp controller is provided that attaches to a lamp fixturevia a specialized port, which may be built-into the lamp's fixture. Lampfixtures that do not include the specialized port may be readilyretrofitted using a retrofitting kit, embodiments of which are describedherein.

In one respect, the invention involves a kit for retrofitting a lamp foruse with a modular lamp controller. The kit includes a port connector, afirst portion of a port adapter, a second portion of a port adapter, anda lock nut. The port connector is configured to accept a plug of themodular lamp controller. The first portion of a port adapter has athreaded section. The second portion of the port adapter has a threadedsection. The first and second portions are configured to be placed inopposing relation about the port connector to securely surround the portconnector while fitting into an opening within a fixture of the lamp.The lock nut screws onto the threaded sections of the first and secondportions of the port adapter while placed in opposing relationsurrounding the port connector to secure the port adapter and portconnector within the opening.

In other respects, the kit may also include a shorting plug configuredto attach to the port connector. The first and second portions of theport adapter may include a rib configured to facilitate installation byhand.

In another respect, the invention involves a method for retrofitting alamp for use with a modular lamp controller. An opening is created in afixture of the lamp. A port connector is surrounded with first andsecond portions of a port adapter by placing the first and secondportions in opposing relation about the port connector. The portconnector surrounded by the first and second portions of the portadapter is placed into the opening. A lock nut is screwed onto rearsections of the first and second portions of the port adapter whileplaced in opposing relation surrounding the port connector to secure theport adapter and port connector within the opening.

In other respects, the method may also include attaching a shorting plugto the port connector. The method may also include connecting wiringfrom the port connector to circuitry within the lamp fixture. Theconnecting of wiring may include connecting the port connector to acapacitor within the lamp fixture. The creating of an opening in thefixture of the lamp may include creating an opening using a knockouttool or a drill.

Other features and associated advantages will become apparent withreference to the following detailed description of specific embodimentsin connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The techniques of this disclosure may be better understood by referenceto one or more of these drawings in combination with the detaileddescription of illustrative embodiments presented herein. Identical orsimilar elements use the same element number. The drawings are notnecessarily drawn to scale.

FIG. 1 is a schematic diagram of a conventional HID lamp.

FIG. 2 is a schematic diagram of a conventional dimming system for usewith an HID lamp.

FIG. 3 is a schematic diagram of another conventional dimming system foruse with an HID lamp.

FIG. 4 is a schematic diagram of a modular lamp controller, according toembodiments of the present disclosure.

FIG. 5 is schematic diagram showing another view of a modular lampcontroller, according to embodiments of the present disclosure.

FIG. 6 is a schematic diagram showing the inside of a modular lampcontroller, according to embodiments of the present disclosure.

FIG. 7 is a flowchart illustrating processes for operating a modularlamp controller, according to embodiments of the present disclosure.

FIG. 8 is another flowchart illustrating processes for operating amodular lamp controller, according to embodiments of the presentdisclosure.

FIG. 9 is a schematic diagram illustrating a mounting adapter assemblyfor use with a modular lamp controller, according to embodiments of thepresent disclosure.

FIG. 10 is an exploded view of the mounting adapter assembly of FIG. 12.

FIG. 11 is a schematic diagram illustrating a laser alignment tool foruse with a modular lamp controller, according to embodiments of thepresent disclosure.

FIG. 12 is a schematic diagram illustrating a modular lamp controllerequipped with two laser alignment tools, according to embodiments of thepresent disclosure.

FIGS. 13A and 13B illustrate alignment principles of a laser alignmenttool, according to embodiments of the present disclosure.

FIG. 14 is a schematic diagram of an interchangeable lens assembly unitfor use with a modular lamp controller, according to embodiments of thepresent disclosure.

FIGS. 15A and 15B are a schematic diagrams showing different views of anassembled interchangeable lens assembly unit for use with a modular lampcontroller, according to embodiments of the present disclosure.

FIG. 16 is a schematic diagram showing the attachment of aninterchangeable lens assembly unit to a modular lamp controller,according to embodiments of the present disclosure.

FIG. 17 is a schematic diagram illustrating a masked lens for use withan occupancy sensor of a modular lamp controller, according toembodiments of the present disclosure.

FIGS. 18A–21B are schematic diagrams illustrating different fields ofoccupancy detection coverage for an occupancy sensor of a modular lampcontroller, according to embodiments of the present disclosure. FIGS.18A, 19A, 20A, and 21A show coverage along a length given the occupancysensor is hanging a certain height above the floor. FIGS. 18B, 19B, 20B,and 21B show coverage along a width given the occupancy sensor ishanging a certain height above the floor.

FIG. 22 is a schematic diagram illustrating another masked lens for usewith an occupancy sensor of a modular lamp controller, according toembodiments of the present disclosure.

FIG. 23 is a schematic diagram illustrating a retrofitting kit for usewith a modular lamp controller, according to embodiments of the presentdisclosure.

FIG. 24 is a schematic diagram illustrating the use of a retrofittingkit, according to embodiments of the present disclosure.

FIG. 25 is a schematic diagram illustrating a control port of a modularlamp controller, according to embodiments of the present disclosure.

FIG. 26 is a block diagram illustrating hardware elements of a modularlamp controller, according to embodiments of the present disclosure.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Modular lamp controllers of the present disclosure address shortcomingsof conventional devices such as those discussed above. Installationcost, mounting and alignment problems, maintenance cost, troubleshootingtime, repair time, and probability of lamp failure are all minimized.

A representative embodiment of a modular lamp controller 400 is shownin, among other figures, FIG. 4. The lamp 107, which may be an HID lamp,includes a lamp capacitor 105 and a port 401. The port 401 is coupled tothe capacitor 105 through wiring 402 and 403. The modular lampcontroller 400 includes a housing 407, a plug 406, a cable 405, acapacitor 416, a switch 408, a transformer 409, a power supply 410, aswitch controller 412, an occupancy sensor 413, impedances 414 and 415,and shorting plug 404.

Plug 406 has a shape complementary to port 401 so that the modular lampcontroller 400 can securely connect to the lamp fixture 108. Indifferent embodiments, the shape may vary. When plug 406 is attached tothe port 401, lamp capacitor 105 becomes coupled to capacitor 416. Inthe illustrated embodiment, the coupling is a series connection. Theoperation of switch 408 correspondingly determines the power state oflamp 107. In the illustrated embodiment, operation of switch 408 togglesbetween a high (full) power state and a reduced (dim) power state. Inother embodiments, power reducing members other than capacitor 416 maybe used. For instance, any suitable device such as one or moreresistors, potentiometers, or the like may be used within housing 407 ofthe modular lamp controller 400 to suitably reduce power output of lamp107.

The nature of switch 408 may likewise vary. It may any type of devicecapable of defining different states. In one embodiment, switch 408 andthe workings of the modular lamp controller 400 may be software-based ora combination of software and hardware, as understood in the art.

In different embodiments, the number of different power states may vary.As illustrated, lamp 107 is provided with two power states: a full anddim power setting. In other embodiments, the number of power states maybe 3, 4, 5, 6, 7, 8, 9, 10, etc. In still other embodiments, if thepower state is configured to be adjusted continuously, the number ofpower states may be infinite. If use of the modular lamp controller 400is not desired, shorting plug 404 may be placed into port 401, and lamp107 will light at full power at all times.

In the illustrated embodiment of FIG. 4, power supply 410 may draw powerfrom current of lamp 107, although in other embodiments, an independentpower supply (not shown) may be used.

Switch controller 412 acts in conjunction with occupancy sensor 413 tooperate switch 408 to control the power state of lamp 107 based uponoccupancy of the space being illuminated. Switch controller 412 refersnot only to the actual mechanism for operating switch 408, but it alsorefers to the host of optional various control electronics that may beincluded within modular lamp controller 400, including but not limitedto user inputs, control ports, and the like described herein. Inparticular, different embodiments of this disclosure involve switchcontroller 412 serving a variety of optional, specialized functions. Forinstance, switch controller 412 may contain logic that facilitatestesting, user settings, internal checks and the like. These optionalfeatures may be implemented through dip switches 603 (see FIG. 6), pushbutton 604 (see FIG. 6), control ports or any other similar mechanism.

FIGS. 9–10, among other figures, illustrate representative embodimentsof a mounting adapter assembly 1200 that facilitates the mounting ofmodular lamp controller 400. With reference to FIG. 9, a mountingadapter 418 is shown having internal threads 1202, external threads1203, and a step 1204. Also illustrated is a jam nut 419, a lock nut1201, a mounting pipe 417, and housing 407 of the modular lampcontroller 400. In operation, lock nut 1201 may be attached to themounting pipe 417. Mounting adapter 418 may then be threaded onto themounting pipe 417 using internal threads 1202. The jam nut 419 may bethreaded onto the mounting adapter 418 using external threads 1203. Thestep 1204 may be placed within the housing 407, and more particularlythe bosses 1205, of the modular lamp controller 400 to rotatably lockthe modular lamp controller 400 (see 503 of FIG. 5, which exemplifies apossible rotation). In other words, the modular lamp controller 400 maybe held in place but allowed to rotate about an axis of the mountingpipe 417. Once the modular lamp controller 400 is aligned through properrotation about its longitudinal axis, it may be locked into place bytightening the jam nut 419 against the modular lamp controller housing407. (See FIG. 10 for an exploded view).

In one embodiment, the alignment of the modular lamp controller 400 maybe accomplished through the use of a laser alignment tool 1400, which isillustrated in, among other figures, FIG. 11. As shown in FIG. 11, alaser 1405, having a power button 1407, may be attached to the housing407 of modular lamp controller 400 via a bracket 1404 to align the unit.The exact location of laser 1405 relative to housing 407 may vary, butin the illustrated embodiment, it hangs near the bottom of the housing.In one embodiment, and with reference to FIG. 11, laser alignment tool1400 may attach to a recess 1401 in the modular lamp controller housing407. In particular, a clip 1403 may fit into the recess 1401. In oneembodiment, clip 1403 may rotate within the recess 1401 to lock thebracket 1404 securely in place. As illustrated, bracket 1404 may beshaped to follow the contour of the housing (see arms 1402, illustratingone representative shape).

Once attached, laser 1405 may be turned on via button 1407 to shine alaser spot onto a target. The modular lamp controller 400 may be rotated(see 503 of FIG. 5) to move the laser spot to locate the target, whichmay be, in one embodiment, the center of a store aisle (see targets 1601and 1602 of FIGS. 13A and 13B). Once the target is located, the modularlamp controller 400 may be locked into place using mounting adapterassembly 1200 and particularly, jam nut 419.

With reference to FIG. 4, the occupancy sensor 413 may include a passiveinfrared (PIR) detector, or any other suitable detection device, and mayoperate with suitable external or integrated optics. One embodiment ofsuitable detachable optics is illustrated in, among other figures, FIGS.14–15. In these embodiments, interchangeable lens assembly unit 1700 maybe attached directly to, and flush with, housing 407 of the modular lampcontroller 400 to form an integral unit and housing (see FIGS. 4 and16). Advantageously, interchangeable lens assembly unit 1700 may beeasily exchanged (e.g., individual lenses 1703 may be changed) ormodified (e.g., masking may be added) without disassembling the entireunit. In FIG. 14, interchangeable lens assembly unit 1700 includes alens retainer 1701, a housing 1702, and a lens 1703. Different lensesmay provide different coverage for the occupancy sensor (see FIGS.18–21), and masking may be added to further modify the shape of thatcoverage (see FIGS. 17 and 22).

If a modular lamp controller 400 is to be used with equipment that doesnot have an external port 401, the port 401 may be readily installedusing a retrofitting kit 2600, which is shown in, among other figures,FIGS. 23–24. With reference to FIG. 23, there is shown a port connector2602, a first portion 501 a of a port adapter, a second portion 501 b ofthe port adapter 501, a lock nut 2601, and shorting plug 404. The firstand second portions 501 a and 501 b have threaded rear sections 2605.With reference to FIG. 24, placing the first and second portions 501 aand 501 b about the port connector 2602 securely surrounds the portconnection 2602 and allows the pieces to be placed into an opening 2701within the equipment. Once placed into the opening 2701, lock nut 2601may be screwed onto the rear sections of portions 501 a and 501 b viathreads 2605 to secure the port connector and port adapter into place(see FIG. 5). Any suitable means may be used to create the opening 2701in the equipment such as a punch or drill, and the shape of opening 2701may vary. When the port connector 2602 is not in use, it may be pluggedwith shorting plug 404.

In one embodiment, the retrofit kit 2600 may include two or more wiresfor connecting the port connector 2602 to the appropriate circuitrywithin the equipment. In one embodiment, wires 2603 and 2604 may beprovided for connecting to capacitor 105 within lamp fixture 108.

Below, individual components associated with the techniques of thisdisclosure are described in greater detail in the context of exemplaryembodiments. Although not so limited, the description below focuses uponthe particular embodiment of FIG. 4 in which modular lamp controller 400uses port 401 to connect to lamp 107 through fixture 108. The capacitor105 inside of fixture 108 is not removed or replaced. The modular lampcontroller 400 is connected to the fixture 108 with flexible cable 405and may be mounted beside lamp 107. Capacitor 416, switch 408, switchcontroller 412, power supply 410, and occupancy sensor 413 with opticsare all inside (or, in the case of the optics, flush and integral with)the housing 407 of modular lamp controller 400.

Specialized Port

With reference to FIG. 4, a modular lamp controller 400 may utilizespecialized port 401 that is installed in lamp fixture 108. Port 401 isaccessible from the outside of lamp fixture 108 and has two electricalconnections 402 and 403. Connections 402 and 403 are notpolarity-sensitive although the port 401 may be keyed. Port 401 mayconnect to either shorting plug 404 or plug 406, which is attached tocable 405. In one embodiment, the connections may be made so that port401 is in series with existing capacitor 105 in lamp fixture 108.

In one embodiment, port 401 may include electrical port connector 2602,one suitable embodiment of which is shown in FIG. 23. The exact shape ofthe port connector 2602 may vary, as will be recognized by those ofordinary skill in the art. Any shape suitable for providing anelectrical connection point is satisfactory. In one embodiment, however,the port connector 2602 and plug 401 may have a unique pin and socketorientation. The unique orientation is not required for utilitypurposes, but the particular design may advantageously become associatedwith, or come to represent, the manufacturer. Further, the uniquearrangement may be beneficial to the customer because the external port401 of lamp 107 is used and intended for lamp control only. Port 401 maybe specifically molded for this application, and the unique nature ofplug 404 may therefore reduce the chance of misapplication.

An installed port 401 allows for easy “plug-in and go” installation.Fixtures 108 may be shipped with a port connector 2602 and shorting cap404 installed by punching out a hole 2701 in an approved location. (SeeFIG. 24). A modular lamp controller 400 is not required to operate alamp 107 that has port 401. A modular lamp controller 400, however, canbe added and removed at anytime without interrupting the lighting of afacility or unhooking or removing any fixtures. This is possible becausethe connections for installing modular lamp controller 400 may beavailable externally to the lamp 107.

The port 401 and modular lamp controller 400 allow troubleshooting to bedone without a tool. Further, one can quickly determine if a problem isassociated with the modular lamp controller 400 or with the lamp 107. Totroubleshoot the lamp 107 by itself, the cable 405 may be removed andthe shorting plug 404 may be installed into port 401.

Using the technology of this disclosure, the installation or removal ofan occupancy sensor 413, residing within modular lamp controller 400,can be done in minutes, without a tool. Prior systems required the lampfixture 108 to be opened and a switch hard wired. (See FIGS. 2–3 (priorart)). This was very time consuming and did not allow for quick changesin the field. It was not feasible to swap components for atroubleshooting aid without unhooking the fixture-wiring in question.Troubleshooting conventional fixtures or occupancy sensors requiredremoving the entire assembly, which can be very costly. Further, openingthe fixture cavity increases the chance for error.

Retro-Fit Adapter for Creating a Port

In one embodiment, port connector 2602 and shorting plug 404 make up aunique connector system that allows the end user the flexibility toconnect modular lamp controller 400. One may bypass the modular lampcontroller 400 using the shorting plug 404 to run the lamp 107standalone (at full power).

Modular lamp controller 400 generally requires port 401 to be installedin the lamp fixture 108. There are at least two ways to achieve this. Ifthe customer is doing a new installation, the lamp 107 may come from thefactory equipped with a suitable port system. A lamp fixture 108 with ahole 2701 made to fit the port 401 is shown in FIG. 4. If, however, acustomer would like to install a modular lamp controller 400 using anexisting fixture (that does not yet have port 401), the fixture 108 willneed to be modified. A retrofit kit 2600 provides that capability (seeFIGS. 23 and 24).

The installation of port connector 2602 to an existing lamp 107 in thefield is straightforward using the techniques of this disclosure. In oneembodiment, a retrofit kit 2600 includes several components, although itwill be understood by those having skill in the art that the specificnumber of components may vary. The first component is a port connector2602. The second component is the shorting plug 404. Components threeand four are right and left portions 501 a and 501 b (here, halves) ofport adapter 501. In one embodiment, there is a lock nut 2601 (which, inone embodiment may be a ¾″ EMT lock nut) and two wires 2603 and 2604,one with quick connectors on both ends (2603) and the other (2604) witha quick connector on one end and the other end open.

To install port connector 2602 using the retrofit kit 2600, one firstremoves the lamp 107 from its mounted location. Next, the fixturehousing 108 is opened and the ballast make and model may be identified.This information may be needed to specify the dimming capacitor size forthe modular lamp controller 400, in embodiments utilizing capacitor 416as a power limiting member. With fixture housing 108 open, onedetermines the mounting location for the port connector 2602 and thenlocates the wires for making the suitable electrical connections. Theconnector 2602 can either be located in the housing cavity or anelectrical wiring box located on some fixtures.

With reference to FIGS. 23 and 24, the retrofit kit 2600 requires a hole2701, such as a ¾″ emt knockout circular hole, to be created. Opening2701 may be either punched out with a knockout tool or drilled with, forexample, a Unibit. Those of ordinary skill in the art will recognizethat other ways to create the opening may be utilized as well and thatthe shape and size of the hole may vary.

With reference still to FIGS. 23 and 24, one places the two retrofitport adapter portions 501 a and 501 b around the port connector 2602 andinstalls the pieces into the opening 2701 (in the illustratedembodiment, a ¾″ emt hole) with the interface of connector 2602 beingexposed to the outside of the housing 108. After the assembly isinstalled into the opening 2701, one secures the port connector 2602 andport adapter 501 into position with lock nut 2601, which may be a ¾″lock nut. The port adapter portions 501 a and 501 b may have a rib 2603molded into them that aids installation. The ribs 2603 allow for fingerinstallation using the thumb and forefinger and also provide a pivotpoint for a screwdriver to remove the shorting plug 404 or the cableassembly 405 (and plug 406).

In one embodiment, to wire the port connector 2602 to the lamp 107, onelocates the required circuit within the lamp fixture 108 and, usingsuitable wires (such as 2603 and 2604) either attaches using quickconnects or may splice as needed with twist-on wire connectors. Thewiring may mimic that shown in FIG. 4. One then reassembles the fixturehousing 108 and installs the shorting plug 404. The fixture 108 is thenready to be reinstalled to its original mounting position and tested.

The shorting plug 404 allows the lamp 107 to be tested and operatedwithout a modular lamp controller 400 installed. If lamp 107 ignites,the installation is correct and it is ready to be put back into service.In one embodiment, housing 407 provides a location for storing theshorting plug 404 when it is removed. (See FIG. 6). If the shorting plug404 is removed from port 401 and replaced with cable assembly 405 andplug 406, lamp 107 may be operated according to the settings describedherein. For example, lamp 107 may be operated in low or full power toachieve dimming of lamp 107 based upon detected occupancy.

If troubleshooting is required, the cable assembly 405 may bedisconnected and the shorting plug 404 removed from the storage location(see FIG. 6) and connected to examine the operation of lamp 107 byitself. Connecting and disconnecting to the port 401 does not requirelamp 107 to be removed, the fixture 108 taken apart, or the capacitor105 in the fixture 108 removed. Lamp 107 may be operated by itself andcomponents may be easily exchanged without moving or taking the fixtureapart or changing any of the wiring. This saves much time duringtroubleshooting and allows one to quickly isolate components withouttaking them apart.

Modular Lamp Controller Cable Assembly

The modular lamp controller cable assembly 405 allows the modular lampcontroller housing 407 to be mounted away from, and not rigidly mountedto, the lamp 107. This can be advantageous because of reducedtemperature and proper and maintained alignment of optics for occupancysensor 413.

Modular Lamp Controller Housing

With reference to FIG. 4, one embodiment of the modular lamp controllerhousing 407 contains a capacitor 416, switch controller 412, switch 408,power supply 410, and occupancy sensor 413 with optics (see, e.g.,interchangeable lens assembly 1700 of FIG. 14). Capacitor 416 may beselected so that the series combination of it and the existing capacitor105 in the fixture 108 burns lamp 107 at low power. Advantageously, thecapacitor 105 in fixture 108 does not need to be replaced, removed, orhave connections changed.

Modular Lamp Controller Hardware/Circuitry

FIG. 26 shows a block diagram of exemplary circuitry hardware 2900suitable for carrying out embodiments of this disclosure. Included arecontroller 2901, sensor 2902, transducer or detector 2903, DIP switchesand push button 2904, external port 2905, power switch and impedance2906 and power supply 2907. Controller 2901 is coupled to sensor 2902and transducer or detector 2903. Together, sensor 2902 and transducer ordetector 2903 form an occupancy sensor, such as occupancy sensor 413.Controller 2901 is coupled as well to DIP switches and push button 2904(pictured in FIG. 6 as 603 and 604) and external port 2905 (pictured as2801 in FIG. 25). Power switch and impedance 2906 and power supply 2907are also coupled to controller 2901.

In one embodiment, controller 2901 may be the commercially availableMICROCHIP PIC12C67X controller, although any number of differentcommercially available devices may be used instead.

Modular Lamp Controller Capacitor

The series topology between capacitor 105 in lamp fixture 108 andcapacitor 416 of the modular lamp controller 400, although a paralleltopology may alternatively be used, is inherently safer because it isless likely that the ballast or lamp will be overdriven. An incorrectcapacitor value will not run the lamp or ballast hotter. If thecapacitor 416 that is installed is too small, lamp 107 will transitionto too low a power and may extinguish. If the capacitor 416 is too big,lamp 107 will transition to a low power higher than possible for thelamp and energy savings will not be as great. If capacitor 416 isreplaced with a short circuit, lamp 107 will burn at full power. Ifcapacitor 416 is replaced with an open circuit, lamp 107 never arcs, butthe ignitor runs on some systems. None of these situations should causecomponents to run at abnormally high temperatures.

With reference to FIG. 6, capacitor 416 is shown as a metal can,oil-filled capacitor. This is just one type of capacitor that may beused. As will be understood by those of ordinary skill in the art, onemay also use plastic case dry capacitors or any other type of capacitorknown in the art. The housing 407 may accommodate many different sizesof capacitors through the use of removable supports or ribs, as shown inFIG. 6. The unnecessary supports or ribs may be removed with pliers oncethe capacitor 416 to be used is known.

Modular Lamp Controller Switch

With reference to FIG. 4, switch 408 is in series with impedance 414 andis in parallel with capacitor 416 and impedance 415. These are in serieswith transformer 409 and lamp 107. When the switch controller 412 turnsthe switch 408 on, lamp 107 will burn at full power. When switchcontroller 412 turns switch 408 off, lamp 107 will burn at the low powerdetermined by the series combination of capacitor 416 and lamp capacitor105 of lamp 107. Impedance 415 provides a discharge path for capacitor416, and impedance 414 may prevent high currents that could damagecapacitor 416.

Modular Lamp Controller Switch Controller

One important function of switch controller 412 is the operation ofswitch 408. In embodiments utilizing occupancy sensor 413, switch 408 isoperated based on an occupancy signal generated by the occupancy sensor413 so that lamp 107 may be made to operate at full power when anoccupant is detected within a field of view and at one or more reducedpower states if there is no occupancy detected.

In one embodiment, switch controller 412 optionally has lamp current,sensor input, user input, timers and memory, and a control portavailable to determine the state of the switch 408. In this way, themodular lamp controller 400 may be configured to work as a group or usedwith external controllers and occupancy sensors, but no extra externalwiring is required for single unit operation.

Since each modular lamp controller 400 may be individually powered bythe current of lamp 107, there is no need for external lamp warm-uptimers or external lamp dropout sensors. In one embodiment, the lampwarm-up and maintenance timers are internal to the modular lampcontroller 400, so incorrect control port wiring will not adverselyaffect the operation of lamp 107. This also allows the use of simplecontrols to force to full power or to force to low power, without theconcern of improper lamp operation.

Modular Lamp Controller Switch Controller—Current Sensing

The current of lamp 107 may be sensed by switch controller 412. Lampcurrent zero crossings may be sensed (see 411 of FIG. 4) with a timedelay through the transformer 409 because it is a component that isalready used and provides isolation. The lamp current can be used toverify internal timing or to determine information about lamp 107.

In one embodiment, only the zero crossings are monitored and written topart of memory. The sensing of the lamp current may be done with aresistor or some other limiting impedance and analog circuitry or an A/Dconverter, as understood in the art.

Lamp current may be monitored directly or indirectly. A known shunt maybe placed in series with the lamp 107, and the voltage across the shuntmay be measured. In one embodiment, the lamp current may be monitored bythe voltage on the secondary of a transformer which has a winding inseries with the lamp 107.

Modular Lamp Controller Switch Controller—Sensor Input

Switch controller 412 receives an occupancy signal, indicating theoccupancy state within the coverage area of the occupancy sensor andoptics, from occupancy sensor 413 so that the switch controller 412 canoperate switch 408 based upon occupancy. Occupancy sensor 413 maycontain one or more active and passive sensing elements. These mayinclude, but are not limited, to acoustic transducers (audible ornon-audible), light sources and detectors (visible or non-visible), andradio frequency transmitters and receivers.

An array sensitive to visible light may be used to provide informationto modular lamp controller 400 about human occupancy in a space. In oneembodiment, one or more video cameras may be used for occupancydetection. A potential problem with this approach, however, is that theoccupant must be illuminated with visible light for the detection tooccur.

An alternative to occupancy detection is to use a smaller number ofelements that are sensitive to a wavelength of light that human bodiesemit. In one embodiment, occupancy sensor 413 may use a multiple elementpyroelectric infrared detector sensitive to light with a wavelengthclose to 9.4 micrometers. This wavelength may be chosen because it isapproximately the specific peak wavelength of a human body. A movinghuman body is a moving source of light with wavelengths close to 10micrometers. Information from a detector sensitive to this light may beused to determine occupancy in a space.

In the same manner, any characteristic of a moving human may beexploited to determine occupancy using occupancy sensor 413. Human bodymotion usually creates sounds which may be detected by a transducer.Human bodies usually reflect some of the sound energy that hits theouter surface. If small wavelength sounds (approximately 1 cm) arebroadcast from a sensor, the reflections of these sounds off ofsurrounding objects (including human bodies) may be detected by atransducer. The broadcast may either be done in a pulsed or continuousmanner. The detection may either be done synchronously or independentlyof the broadcast.

Radio frequency energy may be used in much the same way as acousticenergy. The human body absorbs and reflects radio frequency energy. Theenergy may be broadcast in pulses or continuously. The reflections maythen be detected and used to determine occupancy using occupancy sensor413.

Modular Lamp Controller Switch Controller—User Input

Modular lamp controller 400 may be equipped with one or more mechanismsso that a user can input or select different modes of operation of thedevice. The user may signal modular lamp controller 400 in manydifferent ways. With reference to FIG. 6, the user may set dip switches603 to effect different modes of operation. The different modes ofoperation may include, but are not limited to, different timer settings,sensitivity settings, and function of operation.

The dip switches 603 may be used in conjunction with the push button 604in a sequence of different operations to place modular lamp controller400 into different modes of operation. This allows a limited number ofdip switches and push buttons to provide information limited only by thecomplexity of the input sequence.

In one embodiment, modular lamp controller 400 may respond to thedepression of push button 604 by entering a test mode. By holding downthe button 604, the user may be signaled by the lamp 107 going dim andbright again that the modular lamp controller 400 is functioningproperly. The amount of time that the lamp 107 is at low power duringsuch a test is restricted in order to not affect the warm-up of thelamp. Extended time at low power is not available while a warm-up is inprogress. If the button 604 gets stuck for any reason, the modular lampcontroller 400 may assume the state of the dip switches 603 before thebutton 604 was pushed.

This has at least two advantages over a push button override. The firstis that if the push button 604 is pressed during a lamp warm-up, thetime at low is limited internally to not adversely affect the warm-up.The second is that if the button 604 became stuck for any reason, themodular lamp controller 400 would revert to the settings it had beforethe button push.

In one embodiment, the dip switches 603 and push button 604 may all beconnected through resistors to a single A/D converter pin of a processor(see FIG. 26). Such an embodiment takes advantage of the limited numberof pins available on a currently-available, cost effective processors,such as the MICROCHIP PIC12C67X. Each permutation of a dip switchsetting has a unique voltage range input to the A/D converter. The pushbutton 604 may be connected so that the push button 604 produces aunique voltage range input to the A/D converter within controller 2901of FIG. 26. In one embodiment, this allows 5 switch inputs to be read byone processor pin. When the controller 2901 reads a voltage in the rangeunique to the push button 604, it is considered a button press.

In one embodiment, dip switches 603 may be set to dictate a sensortime-out setting. The sensor time-out setting is the time to dim fromthe last motion sensed. In one embodiment, this setting is adjustablefrom 10 seconds to 64 minutes. In this embodiment, dip switches 603 maybe set as follows to define different time-out settings (“x” representsthe dip switch being “on,” in an up position; “o” represents the dipswitch being “off,” in a down position):

Dip switch number Dim Timer 1 2 3 4 test (5 seconds) ∘ ∘ ∘ ∘  1 min ∘ ∘x  2 min ∘ x ∘  4 min ∘ x x  8 min x ∘ ∘ 32 min x ∘ x 64 min x x ∘

In one embodiment, dip switches 603 and one push button 604 may be usedto place modular lamp controller 400 in a special factory test mode. Thedip switches 603 are configured with three off and one on, asillustrated as follows and the push button 604 is pressed to initiatethe test:

Dip switch number 1 2 3 4 Factory Test ∘ ∘ ∘ x

When the push button 604 is pressed with the dip switches in thepositions shown in the table immediately above, modular lamp controller400 enters a factory test mode. If the dip switches 603 are in any otherconfiguration, the button push (604) will not enter the factory testmode.

In one embodiment, dip switches 603 may be used to force the lamp 107 toa reduced power, or dim, state. This may be done by configuring dipswitches 603 as follows:

Dip switch number 1 2 3 4 Force Dim x x x x

In one embodiment, dip switches 603 may be used to set the sensitivityof occupancy sensor 413. This may be done by configuring dip switches603 as follows:

Dip switch number 1 2 3 4 Low Sensitivity ∘ High Sensitivity x

If further modes of operation are required, the number of dip switches603 may be increased (or decreased, as needed) and/or the sequence ofdip switch combinations with button pushes may be expanded. An examplewould be if the dip switches 603 were first placed all off, followed bya button push 604, followed by the dip switches 603 being placed all on,followed by another button push 604. This unique sequence of input couldsignal modular lamp controller 400 to enter a certain mode of operation.

As will be understood by those having skill in the art with the benefitof this disclosure, a variety of other functionality may be attributedto the dip switches 603 and button 604 to provide additional, optionalfeatures to modular lamp controller 400. Further a keypad or other formof input (not shown) may be configured to interface with the modularlamp controller 400, as understood in the art, to achieve even moreuser-input parameters.

Modular Lamp Controller Switch Controller—Control Port

In one embodiment, a control port 2801 may be made available for theuser. The control port may have four electrical connection points, orpins. The control port 2801 may also have with a removable plug. Theplug may have four wire screw terminals and may be keyed to mate withthe control port in only one orientation. (See FIG. 25).

In one embodiment, the first connection pin is an input/output pin; thesecond connection pin is a force full power pin; the third connectionpin is a force dim pin; and the fourth connection pin is a low voltagecommon reference.

The input/output pin may be internally driven to a high signal level(e.g., ˜27V). The input/output pin may also be examined to determine ifit is being driven high by an external source. This is useful forgrouping modular lamp controllers 400 to function together.

The low voltage commons of modular lamp controllers 400 may be connectedtogether and the input/output pins of multiple modular lamp controllers400 may be connected together. If any one of the modular lampcontrollers 400 drive the input/output pin high, all pins will be drivenhigh. The modular lamp controllers 400 may be configured to drive theinput/output pin high when occupancy is sensed and transition thecontrolled lamps to bright when the input/output pin is driven high.Groups of modular lamp controllers 400 configured in such a manner willall transition the controlled lamps to bright when any of them senseoccupancy.

In one embodiment, the input/output pin characteristics may becompatible with the output of standard occupancy sensors so that thecontrol wire of an occupancy sensor (which, according to manufacture maybe designated by its blue color) may be connected to the input/outputpin, and the ground wire of the occupancy sensor (which, according tomanufacture may be designated by its black color) may be connected tothe low voltage commons. This allows the occupancy sensor to affect thestate of the controlled lamps. This allows extra occupancy sensors to beadded to a group.

In one embodiment, the input/output pin characteristics may becompatible with the input of standard occupancy sensor power packs sothat the control wire of the power pack (which, according to manufacturemay be designated by its blue color) may be connected to theinput/output pin, and the ground wire of the power pack (which,according to manufacture may be designated by its blue color) may beconnected to the low voltage commons for the input/output pin to be ableto affect the state of the relay in the power pack. This allows a singleunit or group of units to control additional loads.

The force full power pin may be active when it is connected to the lowvoltage common pin. This allows a modular lamp controller 400 to beforced into operating lamp 107 at full power with a normally opencontact. Many modular lamp controllers 400 may be connected in parallelto force them all to full power with the same contact.

The force low power pin may be active when it is connected to the lowvoltage common pin. This allows the unit to be forced into operating thelamp at low power with a contact. Many modular lamp controllers 400 maybe connected in parallel to force them all to low power with the samecontact. The modular lamp controller 400 may monitor operation of lamp107 and not allow lamp 107 to be operated at low power during warmingoperations.

The control port 2801 input may be used to determine the state of theswitch 408, timers, and memory. The switch controller 412 may use thecontrol port 2801 to signal or control one or more other device. Forexample, energy monitors are commercially available to record the timethe lamp 107 has been operating in different modes. These may be used tocalculate energy savings. The modular lamp controller 400 may signalother modular lamp controllers. In one embodiment, the modular lampcontroller 400 may use other two way interface means in the controlport. The control port may be fitted with communications means such asradio frequency, power line carrier, infrared, sound waves, or otheravailable method for transferring information between, to, or frommodular lamp controllers.

In one embodiment, there may be a limited amount of power available atthe illustrated four pin control port 2801 whenever the input/output pinis driven high. Modular lamp controllers 400 may have a module (notshown) added to the four pin control port. The module may derive itsoperating power from a battery or the input/output pin. The module mayhave access to the force bright and force dim pins of the four pincontrol port.

In one embodiment, if the modular lamp controller 400 is placed in aspecial mode of operation by a sequence of dip switch settings andbutton pushes, it may write to memory to always drive the input/outputpin high. This will ensure power for the module as long as the lamp 107has power. In this manner, modular lamp controllers 400 may be fieldupgraded without disassembly. Standard low voltage wiring may bereplaced with accessory communication modules that use any other two wayinterface means. For example, radio frequency communication may be used.

Modular Lamp Controller Switch Controller—Timers

In one embodiment, the modular lamp controller 400 may continuously runtimers to aid in monitoring external and internal states. An internalwatchdog timer may be reset during normal program operation. If it isnot reset properly, the modular lamp controller will be reset.

An internal clock of the modular lamp controller 400 may be scaled andused to produce registers that are updated with time values of seconds,minutes, and hours. These are useful for keeping track of timeout valuesspecified by the user input.

In one embodiment, the zero crossings of lamp current may be monitoredand compared to internal timers. This provides a check for the modularlamp controller's timer's operation. If for some reason (EMI pulse orfaulty reset) the prescaler for an internal timer was to be set to anincorrect value, comparison to the zero crossings of the lamp currentwould result in an error, and the modular lamp controller 400 may bereset.

Internal registers and memory may be set based not only on inputs to themodular lamp controller 400, but also on the present state of these sameregisters and memory. If a button push test sequence has been entered,the modular lamp controller 400 will not respond to interface portcommands until the button push test sequence is complete. Input valuesmay be stored in memory to be used later by the modular lamp controller400. For example, the signal input to the modular lamp controller 400from the occupancy sensor 413 caused by background noise when the spaceis considered unoccupied may be used in an occupied state to determinemodular lamp controller 400 signal input response levels.

The time that lamp 107 has been in operation in different modes may berecorded in registers. This is useful for maintaining proper lampoperation. When lamp 107 is transitioned to low power, some registersmay be cleared. These registers may be incremented each second, or otherincrement of time, that the lamp remains in low power in a Lights LowTimer. In one embodiment, the modular lamp controller 400 may force thelamp back to a higher power state (in one embodiment, full power) for aspecified time when the Lights Low Timer indicates that lamp 107 hasbeen operating in low power in excess of a certain time. Forcing a lamp107 that has been dim in excess of a certain time is beneficial inextending the useful life of the lamp, and especially the useful life ofmetal halide lamps.

Extended time at dim may cause less lumen output on some metal halidelamps. Burning the lamps at high power occasionally forces the halidesalts back into the dose and out of any cool spots of the arc tube inwhich they might have collected. This helps preserve the tungstenelectrodes, lumen output, and normal lamp operation.

In one embodiment, one may wish to avoid forcing several dim lamps tofull power at the same time. For example, consider a group of lampsresiding above an aisle of a warehouse. If no one has occupied thataisle in quite some time, all of the lamps would have remained dim foran excessive period. The lamps would therefore benefit from being forcedto a higher power state for a period. However, if all the lamps areforced to full power at the same time, the warehouse aisle would (a)suddenly go very bright, possibly creating a distracting environment and(b) would create an undesirable spike in energy consumption.

To avoid this situation, one embodiment of this disclosure measures howlong a lamp has continuously been in a dimmed state and forces thatdimmed lamp to a higher power state if the timer indicates that it hasbeen continuously dimmed in excess of a predetermined time. By“predetermined,” it is simply meant that the time period is calculatedor otherwise determined automatically or manually by the user. A“predetermined” time may be a random or non-random time period.

In one embodiment, a dimmed lamp may be cycled to a higher power stateafter a randomized, predetermined time. By way of example, if all thelights of an aisle have been dim for about 5 hours, one lamp may beforced bright at 5 hours, 2 minutes. Another lamp may be forced to ahigher power after 5 hours, 8 minutes. Yet another lamp on that sameaisle may go bright after 5 hours, 5 minutes. Still another lamp mayhave been forced to higher power at 4 hours, 58 minutes. In thisembodiment, the randomized time occurs at a random time interval arounda particular time (in this example, 5 hours). In other embodiments, therandomized time may not track so closely around a particular time.

In one embodiment, the determination of a randomized time isaccomplished by reading the passive infrared (PIR) A/D input ofoccupancy sensor 413 (see 2901 and 2902 of FIG. 26) following a warm-upperiod instead of using a separate random number generator, which maywaste needed code space or entail the use of another chip.

There is thermal noise that shows up on the PIR A/D input of occupancysensor 413. Such noise may be filtered out before occupancy isdetermined. However, this noise may be used, prior to filtering andfollowing warm-up to generate a random number. Because the noise isfairly small compared to the limits of the A/D, it mainly affects theleast significant bits of the A/D read. In one embodiment, the firstfour least significant bits may be chosen for random number generationbecause it allows for 15 unique, random possibilities. As will beunderstood in the art, random numbers of any range (e.g., between 1–5,1–10, 1–100, etc.) may be used as well.

The PIR circuit may take up to a few minutes to settle when power isfirst applied to the modular lamp controller 400 and occupancy sensor413. Thus, the reading of the four bits may be performed when themodular lamp controller 400 exits out of its initial warm-up timer. Inone embodiment, the warm-up timer may be between 12–30 minutes, howeverthat range may vary. For example, in another embodiment, the warm uptimer may be between 3–9 minutes.

Four of the eight bits may be recorded as the variable SCRAMBLE. In oneembodiment, if the Lights Low Timer reaches the following value:X hours+(Y hours*(SCRAMBLE/15)),then the modular lamp controller 400 may be forced into a lampmaintenance warm-up, which means that the lamp 107 will get cycledthrough a higher power state, e.g., full power. In one embodiment, theinput/output pin of the control port may go either high or low toinitiate this lamp maintenance warm-up.

Such cycling to a maintenance warm-up after an extended period of beingdim will benefit the lamp 107. In particular, it is believed that suchcycling will make lamp 107 last significantly longer than a lamp that isnot subject to this type of cycling. The benefit may be especially greatfor metal halide lamps.

As will be understood by those of ordinary skill in the art, the times Xand Y listed above may be set to accommodate the particular lamps beingused. This is to ensure proper lamp operation over the life of the lamp.In one embodiment, X=20 hours and Y=3.75 hours. It appears that tobenefit metal halide lamps, X should be about 3 hours. The goal in oneembodiment is to prevent metal halide lamps from operating in low powermode continuously for more than 5 hours.

As will be understood in the art, the variable SCRAMBLE may representany random number lying between any range, and that number may begenerated by any manner known in the art. Likewise, the variableSCRAMBLE may be multiplied or divided by different constants (or noconstants) as desired.

In general, lamp 107 may be cycled by first timing how long the lamp hasbeen in a dimmed state. In one embodiment, this time is stored in alights low timer, and the time itself may be referred to as the lightslow value. The lamp may then be forced to a higher power state (e.g.,full power) when the lights low value exceeds a predetermined time. Thepredetermined time may be set manually or automatically. It may be afixed constant time, a changing time, a random time, a time following acertain pattern or trend, or any other time period. A predetermined timemay be chosen to particularly benefit a certain type of lamp. Forinstance, if one type of lamp benefits by not being continuously dim formore than 2 hours, the predetermined time may be a time period around 2hours. After the lamp is forced to a brighter state, it is returned to adimmed state (the identical dim state prior to going bright or adifferent dimmed state) after a second predetermined time. Like thefirst predetermined time, the second predetermined time is not limitedto a certain value or type of time period. Rather, it may a fixedconstant time, a changing time, a random time, a time following acertain pattern or trend, or any other time period. It may be setmanually or automatically.

In general, the predetermined time at which the lamp is forced to ahigher power state may be a randomized time. By “randomized,” it issimply meant that the predetermined time may have some random element.In other words, the predetermined time may vary in a way following nospecific pattern. In one embodiment, the randomized time may constitutea random time added to a fixed period of time. In another embodiment, itmay be represented by X+Y*(RANDOM/15), where X is a fixed period oftime, Y is a multiplier, and RANDOM is a random number between 1 and 15.In yet another embodiment, it may be a random time subtracted from afixed period of time. In still another embodiment, it may be a randommultiplier of a fixed period of time. The random element of therandomized time may be generated by any of numerous methods known in theart for generating a number following no specific pattern. In oneembodiment, a random number generator may be used. In anotherembodiment, the random element may be obtained from one or more bits ofan occupancy sensor, as discussed above in the context of a specificembodiment.

In one specific embodiment, the randomized time may be representedsymbolically as follows:T=T _(f)(Operator)T _(r)where T is the time at which a dimmed lamp is forced to higher power;T_(f) is some fixed period of time; (Operator) is any mathematicaloperator including but not limited to addition, subtraction,multiplication, exponential, etc.; and T_(r) is a random time (or arandom scalar). As will be understood by those of ordinary skill in theart, T_(r) need not be a “bare” random number—rather, it may be a randomnumber multiplied, divided, added to, subtracted from, raised to apower, etc. of a constant or other factor.Modular Lamp Controller Switch Controller—General Operation

FIGS. 7 and 8 map out a scheme for switch controller function. Inpractice, the functions disclosed in the flowcharts of FIGS. 7 and 8 maybe programmed into a program memory so that a processor causes switchcontroller 412 to perform the functions according to the presentinvention. In particular, the functions disclosed in FIGS. 7 and 8 maybe performed by system 2900 of FIG. 26.

With reference to FIG. 7, the chart 700 starts at RESET (701) andproceeds to START (702). Values are read from memory and timers andcounters are initialized and started during INIT (703). CHECK INPUTS(704) reads all of the inputs and updates timers and counters. Thedecision block (705) uses the information collected in CHECK INPUTS(704) and internal memory to determine if a test button (such as button604) or test button routine is activated. If either is activateddecision block (706) determines if the test button routine is completed.If the test button routine is not started or finished, control passes toexit block 712 with an active test button routine.

If the test button routine is completed, decision block 707 determinesif the button 604 is still activated. An activated button indicates thatthe button is stuck. The user input will be changed to the value it wasprior to the button push and control passes to STUCK (708). If decisionblock 707 determines that the button is not active, the button testroutine may be reset and control passes to exit (712).

If 705 determines that the test button 604 and test button routine areinactive, control passes to STUCK (708) and to decision block 709.Decision block 709 checks to see if there is an active warm-up or lumenmaintenance warm-up. If there is an active warm-up, control passes toblock 710, where the lamp 107 is forced to full power and outputschanged if necessary.

If there is not an active warm-up or lumen maintenance warm-up at block709, the control passes to CHANGE OUTPUTS (711).

FIG. 8 describes a scheme for CHANGE OUTPUTS 711 of FIG. 7.

CHANGE OUTPUTS 711 starts at 711 of FIG. 8 and control passes todecision block 801. If there is a command to force the lamp 107 to highpower, control passes to block 802. Block 802 transitions the lamp 107to high power and changes any other necessary output or internalsettings before proceeding to EXIT OUT 811.

If there are no force to high power commands at 801, 803 checks if thereis a force to low power. If there are any, block 804 sets the lamp 107to low power and changes any other necessary output or internal settingsbefore proceeding to EXIT OUT 811.

If there were no force to low power commands at 803, 805 checks to seeif the input/output pin of control port 2801 is active. If theinput/output pin is active, there is an external device requesting thatthe lamp 107 be operated at full power, and block 806 sets the lamp 107to full power and changes any other necessary output or internalsettings before proceeding to EXIT OUT 811.

If the input/output pin of port 2801 is inactive at 805, 807 checks tosee if the user interface (e.g., dip switches 603) has a force to lowpower. If it does, block 808 sets the lamp 107 to low power and changesany other necessary output or internal settings before proceeding toEXIT OUT 811.

If the user interface did not have a force to low power at 807, 809checks to see if the occupancy sensor 413 indicates that the space isoccupied. If it is, block 810 sets the lamp 107 to full power andchanges any other necessary output or internal settings beforeproceeding to EXIT OUT 811.

If the space is unoccupied at 809.control passes to EXIT OUT 811.

Modular Lamp Controller Power Supply

In one embodiment, power supply 410 for use with the modular lampcontroller 400 uses a small impedance in series with the lamp 107 toprovide power. Providing power to the modular lamp controller 400 fromthe current of lamp 107 has several benefits. For example, the modularlamp controller 400 will only be timing the lamp current warm-up whilethe lamp has current to warm it up and no external power connection isrequired. Nevertheless, it will be understood that a separate powersupply, which does not draw power from the lamp 107, may be used aswell.

Modular Lamp Controller Occupancy Sensor and Optics

In one embodiment, occupancy sensor 413 may be included in the housing407 of modular lamp controller 400 so that a separate sensor doesn'tneed to be connected for control by occupancy. This greatly reduces anypossibility of a bad connection between the occupancy sensor 413 and themodular lamp controller 400 occurring during installation

When the occupancy sensor-to-switch ratio is increased, the amount ofcoverage required per sensor is reduced. When the required coverage isreduced, the probability of occupancy is lower. If each lamp 107 iscontrolled independently, the overall energy consumption should be less.In sum, more sensors to switches means more savings.

Interchangeable Lens Assembly

In one embodiment, a modular lamp controller 400 may be equipped with aninterchangeable lens assembly 1700, which may be an interchangeablepassive infrared (PIR) lens assembly. Use assembly 1700 provides for aneasy and affordable system to retrofit occupancy sensors 413 in thefield or troubleshoot systems without requiring the use of tools.

In the past, replacing a PIR lens would involve removing an occupancysensor from its current location and disassembling it. This is a verytime consuming process and also opens up the chance for errors. Inconventional sensor systems, the PIR lens is fixed, and there is noreplacing the lens. Rather, one is required to purchase a complete newsensor assembly. In the past, there was no real easy way to clean thelens if it became dirty. This, in turn, would directly affect theperformance of the sensor. Along the same lines, it was very difficultto troubleshoot occupancy sensors. Problems include occupancy sensormalfunction, damaged or dirty lens, incorrect lenses for theapplication, or misaligned lenses. Another problem with existingoccupancy sensors is that if you wanted to change the layout of thesensor pattern, again you either disassembled the sensor or purchased anew one.

With reference to FIGS. 14–16, embodiments of the lens assembly 1700 mayinclude the following main parts: the lens housing 1702, the lensretainer 1701, and the lens 1703. Assembled so that the lens retainer1701 and lens 1703 are placed in the housing 1702, the interchangeablelens assembly becomes an integral unit 1801. (See FIGS. 15A and 15B).The lens assembly 1700 may be a standalone unit 1801, but when snappedon to a modular lamp controller housing 407 (see FIG. 16) it becomes anintegral part of the modular lamp controller 400 and housing 407,providing structural strength as well as completing the esthetics.

The lens assembly 1801 also provides the optics for the occupancy sensor413 and protects the PIR detector (or other occupancy detector) fromradiated energy (light and heat) and convection. The protection thusprovided greatly reduces the background noise of the detector. Manydifferent lens patterns may be used (see, e.g., FIGS. 18A–21B), and itwill be understood by those of ordinary skill in the art that theoptions for such patterns are endless. The capability to switch out thelens 1703 (or the entire unit 1801) in the field without tools andwithout having to remove the occupancy sensor 413 represents a greatadvantage over existing, conventional systems. Further, theinterchangeable lens assembly 1700 provides a way to examine anoccupancy sensor 413 for incorrect lenses, dirty lenses, and damagedlenses with out removing the occupancy sensor 413, which representsanother great advantage.

The interchangeable lens system 1700 is easy to use. The firstrequirement is to decide which lens patterns will best fit theapplication (FIGS. 18A–21B). After the lens 1703 has been selected, onesimply aligns the assembled lens assembly 1801 with the bottom of themodular lamp controller housing 407 (see FIG. 16) and pushes up untilthe lens assembly 1801 snaps onto the modular lamp controller housing407. To remove the assembly, one may press in (see elements 1902) andpull down (see element 1903). The lens assembly may be keyed (see 1704and 1705) so that there is a front and rear to the unit.

This keyed feature allows for masking of the lens (see FIGS. 17, 22).FIGS. 17 and 22 show a possible lens mask. With reference to FIG. 22,lines 2503 represent facets, and 2502 represents cut profiles and slots.Depending on the location, various lenslets may need to masked off fromthe lens' line of sight. Cuts in the mask pattern not only allow formasking of individual parts or groups of parts of the lens, but theyalso allow the mask to contour to the shape of the lens. Any other typeof masking known in the art may also be used in conjunction withinterchangeable lens assembly 1700.

The lens 1703 is not necessarily a regular shape like a cylinder. Themask pattern should be fabricated to provide an opaque cover that fitsthe unique lens contours. This allows the end user to create custompatterns for specific applications. By masking, one can select areas ofunwanted detection and help eliminate false triggers. After the unit1801 is installed, one may attach a laser alignment tool, describedimmediately below, and align the occupancy sensor 413.

Laser Alignment Tool

In one embodiment, a laser alignment tool (LAT) 1400 may be providedthat affords a simple and accurate way to adjust and align occupancysensor 413.

In the past, aligning an occupancy sensor was very tedious andunreliable. The only real way to align an occupancy sensor was by trialand error. Most applications require the installer to be elevated abovethe floor in order to install the occupancy sensor. Mounting heights of60 feet are not out of the ordinary. This means that every trip up anddown from the occupancy sensor may take a nontrivial amount of time.Once the installation is complete, installers now usually make theirbest judgment as to the aiming of the sensor. At this point, there isonly two ways to verify the alignment. The installer must get down tothe floor and walk-test the sensor or wait while a second person alreadyon the floor performs a walk-test. A walk-test consists of walking inand out of the desired coverage area to determine if the sensor detectsmotion only in that area. If the sensor detects motion in undesiredareas or does not detect motion in desired areas, the sensor must beadjusted and tested again. This very inaccurate and time-consumingmethod must be repeated for each conventional occupancy sensor.

The large mounting heights make accurate sensor placement critical togood performance. It takes very little adjustment at the sensor (singledegrees) to move the pattern on the floor by feet. An example of aproperly aligned sensor and coverage pattern is shown in FIG. 13A. Anexample of the same sensor and coverage pattern miss-aligned by a coupleof degrees is shown in FIG. 13B.

With reference to FIG. 11, Laser alignment tools (LATs) 1400 of thisdisclosure are designed to provide an accurate method of aligning anoccupancy sensor 413 in a relatively short time. In one embodiment, theLAT 1400 includes a precision molded bracket 1404 and a commercial gradelaser 1405. The molded bracket 1404 is designed to clip on and preciselycradle around the housing 407 without the use of any tools. In oneembodiment, the clip 1403 of the molded bracket 1404 is inserted intorecess 1401 and rotated 90 degrees. This secures the LAT 1400 to thehousing 407. In other embodiments, rotation may not be necessary or maybe less than or greater than 90 degrees.

Another feature of the molded bracket 1404 of the illustrated embodimentis that it is designed to fit precisely around the contour of thehousing 407. Arms 1402 accomplish this in the illustrated embodiment ofFIG. 11. Laser 1405, which may be a commercial grade laser but may beany laser suitable to shining an accurate point of light, may be mountedin the molded bracket 1404 at a 45 degree angle and calibrated to be inthe same axis as the bracket 1404. Those of ordinary skill in the artwill recognize, however, that any other angle may be used and the LAT1400 may be mounted on a different portion of the modular lampcontroller 400 (or integrated with the modular lamp controller). Thecombination of these features gives the installer a very fast, simple,and accurate method of aligning the sensor without ever leaving theinitial installation location.

A typical sensor alignment procedure according to embodiments of thisdisclosure starts with clipping the LAT 1400 onto a pre-mounted modularlamp controller 400 equipped with an occupancy sensor 413. The laser1405 is activated by pushing the maintained on/off button 1407 at theback of the laser. This will project a laser dot image on the floor inline with the main axis of the sensor (see FIGS. 13A and 13B). The unit400 may then be rotated about the mounting adapter (503 of FIG. 5) untilthe laser dot is projected in the middle of the isle or in line with anypredetermined target (FIGS. 13A and 13B). When the sensor is orientedcorrectly, one simply tightens the jam nut 419 and locks the modularlamp controller 400 in position. Depending on location, one may need tocross check the alignment by using a second LAT 1400 mounting feature(FIG. 12). In FIG. 12, although the two LATs are shown with a 45 degreeangles 1501 and 1502, it will be understood that any other angle may beused. Other embodiments may utilize one (or zero, if laser alignment isnot needed) LATs 1400, as desired.

The housing 407 may be designed with a second LAT 1400 mounting feature,which in one embodiment may be 180 degrees from the original mountingfeature (FIG. 12). By cross checking, the installer can (a) verify thatthe modular lamp controller 400 is plumb with the floor and makeadjustments if necessary and (b) be confident that the modular lampcontroller 400 is aligned correctly without ever leaving theinstallation location. There are various mounting applications were themodular lamp controller 400 may be mounted too close to something like abeam, column, or wall and one of the LATs 1400 would not be accessible.

Mounting Adapter Assembly

In one embodiment, and with reference to FIGS. 9 and 10, a mountingadapter assembly 1200 may be utilized to mount a modular lamp controller400. The mounting adapter assembly 1200 is a system to mount, align, andlock into position without requiring the use of a tool.

In the past, occupancy sensor mounting and alignment was difficult andtime consuming. It was difficult because the preferred mounting locationwas on the lamp fixture 108. The most common place for mounting was thelamp diffuser or reflector. The first problem with the diffuser wascompatibility, considering the many different diffuser sizes and shapesavailable.

Fixture assemblies are typically mounted with a hook-and-eye typesystem. This allows the fixture to swing freely if acted on by anexternal force. At least two problems come out of this fixture mountingsystem. First, the added weight of the sensor mounted to the diffusercreates an unbalanced condition, which often skews the lamp and anyoccupancy sensor. This makes it very difficult to align the occupancysensor and sometimes requires a ballast to be added. The second problemrelates to the free-swinging nature of the fixture. After an occupancysensor has been aligned, any movement of the fixture due to contact orairflow immediately nullifies or introduces error to the alignment.

When mounting an occupancy sensor on a diffuser, it must be attached tothe exterior of the diffuser so that it does not block that light fromthe lamp. It must also be aligned with the coverage area. The occupancysensor must be attached at a location around the perimeter of thediffuser that allows alignment with the desired coverage area, and oftenthe mounting bracket has to be bent to center the pattern within thecoverage area. This is not a very accurate method.

Mounting and aligning according to techniques of this disclosure usingmounting adapter assembly 1200 is fast and effective. Unlikeconventional systems, the occupancy sensor 413 need not be mounteddirectly on the lamp fixture 108. This eliminates the previous problemsof fixture assembly alignment and movement.

One embodiment of a suitable mounting system is shown in FIG. 9. There,element 417 shows a rigid mounted ¾″ EMT mounting pipe, although it willbe understood that other mounting pipe sizes may be used. Pipe 417 maybe mounted directly to a building's framework using any of many industryapproved mounting methods.

With reference still to FIG. 9, once the mounting pipe 417 has beenmounted and plumbed, installation begins. A lock nut 1201 (which may be¾″ EMT lock nut) is threaded onto the already mounted pipe 417. This isa safety requirement. The two parts (418 and 419) of the mountingadapter assembly 1200 are attached next. The mounting adapter 418 andjam nut 419 are threaded onto pipe 417. Once the mounting adapter 418 ishand tight, one can lock into place with the lock nut 1201.

The mounting adapter 418 is designed with at least three usefulfeatures. The first feature is the internal threads 1202 used formounting to a mounting pipe 417, which may be in one embodiment a ¾″ EMTpipe. The second feature is the external threads 1203 used for locatingjam nut 419. The last feature is a step 1204, which may revolve aroundthe center axis of the modular lamp controller 400 and can be used forlocating, supporting, and locking the modular lamp controller 400 intoplace.

The jam nut 419 should be threaded tightly against the mounting adapter418. This will ensure enough room to install the modular lamp controller400. The housing 407 of the modular lamp controller 400 may have ahelpful feature relating to the mounting adapter assembly 1200. Thisfeature includes of two bosses 1205 that extend out past center toencompass the step 1204.

When the housing 407 is installed over the mounting adapter assembly1200 (see FIG. 10), the modular lamp controller 400 can hang withoutfurther support and rotate freely about the axis of the mounting pipe(see 503 of FIG. 5). This feature allows the installer to complete othertasks before finalizing the installation. When the installer is ready,housing 407 may be secured with screw 1207 or another fastening member.This secures the mounting adapter assembly 1200 to the housing 407 butstill allows for full rotation of the housing (503 of FIG. 5).

The capability to rotate the modular lamp controller 400 freely allowsfor easy and precise alignment. The laser alignment tool 1400 may beattached for precise adjustment. The laser alignment tool 1400 indicatesa location below modular lamp controller 400 that is in line with theoptics of the occupancy sensor 413. When this indicates that the opticsare in line with a desired area or target, the occupancy sensor 413 isin the correct position. When the occupancy sensor 413 is in the correctposition, the jam nut 419 may be tightened against the modular lampcontroller housing 407 to lock everything into place. (See FIG. 10) Thislocks the modular lamp controller 400 into position because as the jamnut 419 is tightened up against the modular lamp controller housing 407,the mounting adapter 418 is pulled by the jam nut 419 and traps themodular lamp controller housing 407 into place (see FIG. 10).

Following mounting, the modular lamp controller 400 is ready to betested. If any further adjustments are needed, the jam nut 419 maysimply be loosened and the modular lamp controller 400 readjusted.

As will be readily understood by those of ordinary skill in the art, themethod described above is not the only mounting option for the mountingadapter assembly 1200. If there is no need to access the inside of theunit, the modular lamp controller 400 may be pre assembled including themounting adapter assembly 1200. This may be done on the ground or at adifferent location than the final location. The completed modular lampcontroller 400 can be threaded onto, for example, a ¾″ EMT pipe andsecured by the lock nut 419. The aiming of the modular lamp controller400 is the same as above.

The following examples are included to demonstrate specific,non-limiting embodiments of this disclosure. It should be appreciated bythose of skill in the art that the techniques disclosed in the examplesthat follow represent techniques discovered by the inventors to functionwell in the practice of the invention, and thus can be considered toconstitute specific modes for its practice. However, those of skill inthe art should, in light of the present disclosure, appreciate that manychanges can be made in the specific embodiments which are disclosed andstill obtain a like or similar result without departing from the spiritand scope of the invention.

EXAMPLE 1 Product Specifications of Exemplary Modular Lamp Controller

-   For use with CWA (Constant Wattage Auto-Transformer) ballast's-   Lamp Type Controlled: 175 W to 1,650 W Metal Halide 175 W to 720 W    Pulse Start Metal Halide 250 W to 1,000 W High Pressure Sodium-   Ballast Compatibility: Compatible with every manufacturer of CWA    ballast's-   Initial Lamp Warm up time: 15 minutes-   Warm up Time if lamp goes out: 15 minutes after lamp current is    detected-   Lamp switching: Solid state switching and microprocessor watch dog    provides reliable zero cross voltage switching from low to high and    zero cross current switching from high to low. Inrush protected. p0    Continuous Dim Lamp Protection: The microprocessor monitors    continuous dim time of the lamp. Each lamp bright cycle resets this    timer. If lamp is dimmed continuously for 24 hours, lamp is    automatically cycled to full power for 15 minutes to increase lamp    life.-   Capacitor: Series dim capacitor is mounted inside module. Maximum    capacitor size 3⅞″ D oval. Capacitor value is selected based on    ballast manufacturing specifications.-   Sensor Self-adjusting: Digital microprocessor constantly adjusts    sensitivity for optimum performance.-   Sensor Optics: 9.6 square inches of optical lens @ 2.15″ focal    length. (For long range sensing applications, the greater optical    area and longer focal length increase performance).-   Sensor Range Pattern: (4) interchange lens options (3 aisle lens for    mounting 12′ to 50′ above floor & 1 square area lens) available to    match control application. Each lens is color-coded.-   Laser alignment: Allows accurate aiming of sensor pattern to within    +/−2 degrees-   Sensor masking: Externally mounted, black sensor mask covers half    the sensor lens for asymmetrical coverage and is easily modified to    mask out motion from unwanted areas.-   Sensor Timer Settings: 2, 4, 8, 16, 64 min, and 10 second test mode-   Force Dim Option: After lamp warm up, sensor is disabled and lamp    will dim continuously. Continuous dim protection is still active.-   Self Diagnostics Test Button: Momentary push button initiates self    diagnostic to verify controller is functioning properly.-   User Interface: 4 dip switches and self diagnostic push button-   Mounting: ¾″ Threaded pipe mounting adapter with security screw.    Mount sensor lens even or below fixture reflector.-   Power Cord: Interchangeable 3′ and 6′ power cords with plug.-   Operating Temperature Range: (Indoor use only): −22 degrees F. to    +149 degrees F. (−30 degrees C. to +65 degrees C.)-   Weight: Less than 3 lbs. (without dim capacitor installed)-   Dimensions: 13.25″ H×5.5″ W×2.6″ D (33.6×14.0×6.6 cm)-   Construction: Rugged, high impact, injection-molded plastic.

With the benefit of the present disclosure, those having skill in theart will comprehend that techniques claimed herein and described abovemay be modified and applied to a number of additional, differentapplications, achieving the same or a similar result. The claimsattached hereto cover all such modifications that fall within the scopeand spirit of this disclosure. For example, although the description ofthis disclosure focuses upon embodiments well suited for use with highintensity discharge lamps, those of ordinary skill in the art having thebenefit of this disclosure will recognize that the inventions describedherein may be used to control a wide variety of different types of lampsand equipment in general. By way of example, the modular lamp controllerconcepts of this disclosure may be applied to control lamps of all typesand any equipment that may benefit from operating at one or more reducedpower states. Although the description of this disclosure focuses uponembodiments in which laser alignment tools and mounting assembly unitsare used in conjunction with modular lamp controllers, it will beunderstood that those tools may be used as well to align and mount anyequipment, including but not limited to stand-alone occupancy sensors.

1. A kit for retrofitting a lamp for use with a modular lamp controller,the kit comprising: a port connector configured to accept a plug of themodular lamp controller; a first portion of a port adapter having athreaded section; a second portion of the port adapter having a threadedsection; the first and second portions being configured to be placed inopposing relation about the port connector to securely surround the portconnector while fitting into an opening within a fixture of the lamp;and a lock nut configured to screw onto the threaded sections of thefirst and second portions of the port adapter while placed in opposingrelation surrounding the port connector to secure the port adapter andport connector within the opening.
 2. The kit of claim 1, furthercomprising a shorting plug configured to attach to the port connector.3. The kit of claim 1, the first and second portions of the port adaptercomprising a rib configured to facilitate installation by hand.
 4. Amethod for retrofitting a lamp for use with a modular lamp controller,comprising: creating an opening in a fixture of the lamp; surrounding aport connector with first and second portions of a port adapter byplacing the first and second portions in opposing relation about theport connector; placing the port connector surrounded by the first andsecond portions of the port adapter into the opening; and screwing alock nut onto rear sections of the first and second portions of the portadapter while placed in opposing relation surrounding the port connectorto secure the port adapter and port connector within the opening.
 5. Themethod of claim 4, further comprising attaching a shorting plug to theport connector.
 6. The method of claim 4, further comprising connectingwiring from the port connector to circuitry within the lamp fixture. 7.The method of claim 6, the connecting wiring comprising connecting theport connector to a capacitor within the lamp fixture.
 8. The method ofclaim 4, the creating an opening in the fixture of the lamp comprisingcreating an opening using a knockout tool or a drill.